Assessment and planning of the electrical systems in Mexican refineries by 2014

Transcription

1 122 Abstract Assessment and planning of the electrical systems in Meican refineries by 2014 Luis Iván Ruiz Flores 1, José Hugo Rodríguez Martínez 1, Guillermo Darío Taboada 2 y Javier Pano Jiménez 2 Nowadays the refining sector in Meico needs to increase the quantity and quality of produced fuels by installing new process plants for gasoline and ultra low sulphur diesel. These plants require the provision of electricity and steam, among other services to function properly, which can be supplied by the power plants currently installed in each refinery through an epansion of their generation capacity. These power plants need to increase its production of electricity and steam at levels above their installed capacity, which involves the addition of new power generating equipment (gas or steam turbo-generators) as well as the raise of the electrical loads. Currently, the Meican Petroleum Company (PEMEX) is planning to restructure their electrical and steam systems in order to optimally supply the required services for the production of high quality fuels. In this paper the present status of the original electrical power systems of the refineries is assessed and the electrical integration of new process plants in the typical schemes is analyzed. Also this paper shows the conceptual schemes proposed to restructure the electrical power system for two refineries and the strategic planning focused on implement the modifications required for the integration of new process plants that will demand about 20 MW for each refinery by The results of the analysis allowed to identify the current conditions of the electrical power systems in the oil refining industry or National Refining Industry (NRI), and thereby to offer technical solutions that could be useful to engineers facing similar projects. Keywords: clean fuel, combined efficiency, conceptual design, economic assessment, electrical net, electrical system, electrical transformer, interrupt capacity, load flow, refinery power plant, refining, short circuit, synchronization bus, three wind. 1 Instituto de Investigaciones Eléctricas (IIE) 2 Petróleos Meicanos (PEMEX)

2 Assessment and planning of the electrical systems in Meican refineries by Resumen Hoy en día, el sector de refinación en Méico necesita aumentar la cantidad y calidad de los combustibles producidos, mediante la instalación de nuevas plantas de proceso para la gasolina y el diésel ultra bajo en azufre. Estas plantas requieren el suministro de electricidad y vapor de agua, entre otros servicios, para que funcione correctamente, los cuales pueden ser suministrados por las fuentes de generación instaladas en cada una de las refinerías y a través de una epansión de su capacidad de generación. Estas centrales eléctricas necesitan aumentar su producción de electricidad y vapor de agua a niveles por encima de su capacidad instalada, lo que significa integrar nuevos equipos de generación de energía (gas o vapor turbogeneradores), así como el aumento de las cargas eléctricas. En la actualidad, Petróleos Meicanos (PEMEX) tiene la intención de reestructurar sus sistemas eléctricos y de vapor, a fin de suministrar de forma óptima los servicios requeridos para la producción de combustibles de alta calidad. En este artículo se presenta la situación actual de los sistemas de energía eléctricas originales de las refinerías y se evalúa la integración eléctrica de las plantas de proceso en los nuevos esquemas típicos. También se presentan los esquemas conceptuales propuestos para reestructurar el sistema de energía eléctrica para dos refinerías, cuya planificación estratégica se centró en la aplicación de las modificaciones necesarias para la integración de nuevas plantas de proceso que demandarán alrededor de 20 MW para cada refinería en el año Los resultados del análisis permitieron identificar las condiciones actuales de los sistemas de energía eléctrica en la industria de refinación de petróleo o de la Industria Nacional de Refinación (INR), y por lo tanto ofrecer soluciones técnicas que podrían ser útiles para los ingenieros que desarrollan proyectos similares. Introduction Currently, the oil refining industry is in upgrading process of its electric system in order to supply the oil demand. Every oil refinery are linked up to The National Electrical System (NES) to ensure the electrical energy continuity in eventuality situations; however, the acquisition energy cost and the fees payment is up to USD $ per month. In the other hand, because of the new requirements NRI has presented new action schemes, like migrate from 13.8 kv to 35.5 kv, and to 115 kv in some cases (García et al, 2008). Moreover, there are operative limitations which generate non programmed shutdowns, for eample: between 2005 and 2006 there were three non programmed stops because of the generation sources floating neutral (García et al, 2008; (García et al, 2005). Additionally NRI tends to process different crude oil from the ones that produced more than 30 years ago, that means that electrical systems must evolve. NRI has taken in account an investment for electrical reconstructing for more than USD $ 120 million only for one refinery. For that reason, and to support the actual and future electric demands, it is necessary to use supply steam, compressed air, water and electric energy in the net decades. The purpose of that document is to give the eperience, obtained through an equipment integration analysis, and new electric generators which permit it to be self-sufficient to reach an electrical power of 120 MW with a 34.5 kv level and 320 MW with a 115 kv level as means of distribution. The results presented here can be useful to solve problems in similar projects. Background Current Schemes Instituto de Investigaciones Eléctricas (IIE), Meican public decentralized organism created for technological researches, has been working with NRI since 2002 about a) development of conceptual engineering for electrical systems, b) technical-financial feasibility study, c) electrical equipment specifications, d) user bases, e) tender bases, f) the analysis of power electrical systems to implement specific solutions for the electrical, mechanical and control equipments. NRI consists of si refineries in Meico: Cadereyta, Nuevo León (HRLS); Cd. Madero, Tamaulipas (FIM); Tula, Hidalgo (MHI); Salamanca, Guanajuato (AMA); Minatitlán, Veracruz (LC) y Salina Cruz, Oaaca (ADJ). In the table 1, it is shown the results of the work between IIE and NRI which generate the necessity of the construction of 4 electric generators with heat recovery, 1 steam boiler, 2 electrical upgrading with the migration of the 13.8 kv to 34.5 kv BS in two refineries from the north of Meico, and 1 electrical upgrading of 13.8 kv to 115 kv in one refinery from the center of Meico. The modernization of every SEP was regarded because of the convenience of

3 124 the implementation of 2 alternatives for the new generation unities: a) with a gas generator and b) with a steam generator. The table 2 shows the comparison of the alternatives to take the decision to integrate a gas generator into the new schemes. Taken decisions for upgradings systems Many specialists take part into the electrical upgrading asset, somebody have been developed the conceptual engineering and others decide whether every project has economical feasibility for its development. For eample, NRI has different sections which take part into the project decisions like: a) Investment Analysis Department (GAIGO: Gerencia de Análisis de Inversión), b) Projects Development Engineering Department (DCIPD: Dirección Corporativa de Ingeniería y Desarrollo de Proyectos), c) Operations Department (DCO: Dirección Corporativa de Operaciones), d) Proscess Engineering Department (GIP: Gerencia de Ingeniería de Procesos) and e) The local users of every refinery. The intervention of NRI entities let the management and development of projects which needs a future: a) supply of the same actual demand of energy, b) the integration of the new generation modules; c) high resistance grounding neutral method; d) the ideal energy flow; e) the charges redistribution and f) the energy supply of the Clean Fuel Projects Quality (CFPQ) mentioned in (García et al, 2009; Alcaraz et al, 2008). In the figure 1 it is shown the IIE participation and the awaited electric upgrading projection for the Table 1. Results of IIE and NRI together working by now. Concept Refineries HRLS FIM MHI AMA LC ADJ Conceptual engineering Generator tender PCC Loads tender Gruunding c/ High impedance Technical-economic feasibility Electric upgrading Technical consultant tender Steam boiler tender Table 2. Comparison between gas generator steam generator. TURBOGENERATOR STEAM This alternative needs: (180 t/h) additional steam generator to ensure eistent production and rehabilitation TG1 and TG2 eisting electric generators rehabilitation To wide the cooling system in case of partial condensation work. That means an increase water consumption in the refinery The actual electric system improvement Acquiring the turbogenerator and their peripherial Advantages: Use oil or/and gas as fuel in boilers This schemes are well known in the refineries Disadvantages: There is no improvement in global efficiency of the refinery Stop the refinery process to make the new turbo generator connection TURBOGENERATOR TO GAS Heat retriever to seize gases combustión and steam generator of 19 bar TG1 and TG2 eisting steam and electric generator rehabilitation To analyze the gas availability and to ponder prices volatility The actual electric system improvement Acquiring the turbogenerator and their peripherial There is a decrease in the consumption of oil in the refinery (It is saved medium pressure in boilers) Use diesel and/or gas as fuel in gas turbines There is a permanence of actual water There is an improvement in global efficiency of the refinery It is necessary to consider that there is a major maintenance if diesel is burned, moreover the heat retriever will need soot blower The users refinery do not know well those schemes Conceptual engineering of actual and typical future electrical system NRI actual typical electric systems The electrical actual net of the si refineries in Meico, have limitations in 13.8 kv distribution interruptive capacity switchgear. The actual average capacity of those switchgear is 31.5 ka short circuit in case of three-phase failure (Icc 3F) ka means 100% of the capacity which support the equipments according to manufactures production line; however it is considered to maintain a 20% security margin for future epansion in that level.

4 Assessment and planning of the electrical systems in Meican refineries by Figure 1. Work together between IIE and NRI for the eecution of upgradings projects. Figure 2. Representative scheme of a refinery which has two generation sources synchronized with NES. The generators neutral was connected to a common point named neutral bus or neutral switchgear through an interrupter and grounded through a low resistence bank. Only the link transformer neutral with the public net and a generator neutral are grounding, the rest of the generators work ungrounded. They have a redundant system to supply energy with at least two generation sources trough the 13.8 kv distribution buses or the eistent 14.6 kv link interrupters called selective secondary. In case of contingence, if a switchgear gets out of maintenance, the charges can be transferred to their adjacent switchgear or through the synchronization bus to obtain the an energy flow that supplies electric energy in two inclusive subsystems. Electrical system with three generation sources Figures 2, 3 and 4 shows the actual scheme of a refinery which has two power plants, that supply the electric energy (92 MW) and the steam that needs their process plants with two generators. The power plant No. 1 has a 18 MW (TE-1) turbo epander installed in the catalytic plant and two 32 MW steam turbo generator (TG1 and TG-2) and four boilers that generate 60 kg/cm 2 man steam and a boiler that generates 20 kg/cm 2 man steam. The generators TG-1 and TG-2 work with etraction, giving 20 kg/cm 2 man steam. The power plant No. 2 has two boilers which gives 20 kg/cm 2 man steam (B-001A and B-001B) and two boilers that gives kg/cm 2 man (B-002A and B-002B). Additionally, the refinery has three energy flows, two of 230 kv and one of 115 kv that come fron NES. Every flow of 230 kv has a 84 MVA maimum capacity and the one of 115 kv has a capacity of of 20 MVA. The 115 flow is connected to the TDP-3 TDP-3 and currently is out of service because is used as backup in one of the 230 kv energy flow, that way there is a deficit energy supply in the refinery through link substations. Finally, all the 13.8 kv distribution switchgears has an interruptive capacity and the 31.5 ka design for the symmetrical three phase short circuit flow. In actual conditions, the power plant does not supply the total electric energy necessity in the 92 MW refinery, therefore is necessary the echange of 40 MW from other sources of NRI or NES. Electrical system with more than 4 generation sources Figure 5 shows the actual scheme of a refinery with more than for electric generators divided into two thermoelectric plants which supplies a charge average of 97 MW. The plant 1 has 6 boilers called

5 126 In actual conditions, the energy plant does not cover the total electrical energy necessity of the 97 MW refineries it is necessary 14 MW energy echange from other NRI or NES work center. Figure 3. Typical actual (representative) scheme of a steam generation refinery with two electrical generators synchronized with NES. Figure 4. Typical actual (representative) scheme of a steam generation refinery with two electrical generators synchronized with NES. MP-B1, MP-B2, MP-B3, MP-B4, CB2 y TG-4, and 4 turbo generators called TG-1, TG-2, TG-3 and TG-4. The turbo generators TG-1, TG-2 and TG-3 are designed to work at full condensation, while TG-4 turbo generator is designed to work with steam etraction and condensation. The switchgear from Plant 1 has 31.5 ka interruptive capacity. The plant 2 has 3 boilers named CB-5, CB-6 and 2 turbo generator named TG-5 and TG-6. The turbo generators TG-5 and TG-6 work with steam etraction. The 2 plant switchgear has 41 ka interruptive capacity. These descriptions indicate a conceptual design must have a rational procedure to determinate the best plan generated by at least three conceptual scheme models. In other articles published by these authors, they present recommendations which have been usual to modify schemes showed in figures 2 and 4 (Ruiz et al, 2009). To describe the alternatives chosen for NRI electrical upgrading there will be presented the factors that suffer changes because of project made by IIE and the benefits that will receive in Future electrical system for NRI The generation capacity of the majority of the si refineries, is practically the same as charge demand (100 MW). There is no warranty in the continuous energy supply, not even for the actual process plant in case of emergency, not even for the new plants. For that reason, it was regarded to reconstructing the tension to 34.5 kv level in two refineries. In this clause there will be included the electrical schemes which will be established for the figures showed in figures 2 and 4. Every scheme showed, for the 3-generator refinery and for 4-generator refinery, was analyzed through stable state evaluation of the electrical system performance with three phase short circuits, charges flow, tension falls, power factor and tension regulation (Ruiz et al, 2009).

6 Assessment and planning of the electrical systems in Meican refineries by The main specification of the electrical equipment for the refineries electrical upgrading implementation embrace take a decision in economical investment: 1) Electrical integration generators, 2) Insulated switchgear technology in SF6, 3) The power factor technology with double cooling (OA/FA) using commercial connections as multi contact elbow bushing and also load tab changer, 4) The decision of installing grounding with zig-zag transformers, 5) The use of charge circuit for 13.8 kv and 34.5 kv with intertwine polyethylene insulation (XLPE) at 133% in insulation level and 6) the integration of new control systems to the SCOA systems. Figure 5. Typical actual (representative) scheme of a steam generation refinery with more than four electrical generators synchronized with NES. The schemes to be established of the refineries to migrate at a 34.5 kv distribution level will have supply and installation phases. The supply, installation, integration, field proves, training and putting into service are divided as the following: Integration of an electrical generator among MW capacity for refineries of three generators and MW for refineries of more than four generators to supply the actual energy supply. Upgrading of 13.8 to 34.5 kv bus synchronization for both refineries. Integration of an electrical generator among MW capacity for refineries of three generators and MW for refineries of more than four generators to supply the future CFPQ demand. Electrical distribution in switchgear for CFPQ. High resistance grounding of the three generation sources. Integration of new systems into the Advanced Operational Control System (SCOA: Sistema de Control Operacional Avanzado). Table 3 shows a tentative programming but no limiting of the electric upgrading projects eecution in refineries. The programming will depend on availability budget NRI and on fiscal year. In figures 6 and 7, the descriptive schemes but non limiting wich will be implemented for the refineries of three or four electric generators are shown. The figures represent an integral electrical scheme for eecution of the same economical eercise. The difference in economical investment for the figure 6 scheme is more than USD $ 50 million, different from figure 7 scheme which means more than USD $120 million. The benefits they get once those schemes are established are 1) The new scheme will permit an optimal electrical power flow to the charges, in all the operation sceneries, without bottlenecks, 2) In contingence conditions, charges fall are less than +- 5% in all charge buses, 3) The backup accomplishment has the capacity to substitute a generator of some of the plants, in case of it is out of service, because of fall or because of maintenance, 4) Plants can receive a 18 MW additional integration, 5) All the plants electrical net has only a neutral grounded for the grounding fall-protection schemes simplification. The 115 kv winding has its neutral firmly grounded. The 34.5 kv synchronization bus has a zigzag transformer. The generators neutral is high resistance grounded,

7 128 Table 3. Tentative programming of the future electrical system implementation phases in NRI. Programming per three months Fases T TG 130 = = = 2 BS Upgrading 115 = = 3 Power circuits 90 = = = 4 2º TG 112 = = 5 PCC Distribution plants 110 = = = 6 Grounding with high Z 108 = = 6 Systems integration 100 = = = = = Notes: T Working days Z Impedance TG Electric generator = Three months Parallel solutions to the continuity projects The actual refineries has an energy deficit and an additional 20 MW demand, that requirement could be supply with a new electrical generator integration. The authors propose a transition stage because of the mentioned changes and because of the cases that is necessary to migrate from 13.8 kv to 34.5 kv. That stage can be implemented in case the refineries do not have budget availability for an integral project in one eecution and at the same time of 1 and 2 phases (table 3). Figure 6. Descriptive scheme but non limiting of SB in 34.5 kv selected for the electrical reconstructing of figure 2 scheme. 6) If a generator is out of service, there will be capacitors banks which can supply the necessary reactive power to keep 0.9 power factor in bound accomplishment. There are many other benefits mentioned in references (García et al, 2008; Ruiz et al, 2005). The net section will present the transition alternative to connect an electrical generator to the actual typical electrical system in a refinery (figure 8). The analysis shows the integration of the first generator using two alternatives for its integration: a) through a limiting reactor of ohms short circuit, 1500 A in a serial configuration with the generator and b) through a three winding transformer of 35/35/35 MVA, 13.8/14.4/34.5 kv, where the terminals of TG- n1 generator are connected to the 13.8 kv winding, its distribution charge switchgear to the 14.4 kv winding and the 34.5 kv winding will be integrated to the future project: 34.5 kv synchronization bus implementation. To determin the technical and economical most feasible option to connect a new electrical generator to the electrical actual system in a typical refinery, there were regarded the two mentioned alternatives by means of a short circuit values analysis and power flow in main charge buses with

8 Assessment and planning of the electrical systems in Meican refineries by established operation conditions eclusively for the first generator. Integration of a generation module in the actual electrical system: comparison with the use of reactor vs the use of three winding transformers The use of three winding transformers in NRI is not yet well known, even though in other oil refined centers like Deer Park in Teas, USA, is used that kind of technology. Figure 7. Descriptive scheme but non limiting of SB in 34.5 kv selected for the electrical upgrading of figure 4 scheme. Figure 8. Descriptive scheme but non limiting of a parallel alternative to connect a generator with the refineries actual scheme. The analysis ponder the evaluation in stable state of the electrical system performance with three-phase short circuit charges, flow charges, tension falls, power factor and tension regulation. There were analyzed two scenarios including: A) All the electrical energy sources in 115 MW operations and b) An electrical energy source aou of service with a MW charge. According to results, it is showed that both alternatives are operatively reliable, however, the alternative of integrating the first TG-8 generator through a limiting reactor has major tension falls because of the impedance that affects the electricity flow. Also, that implies overworking of the generator TG-8 in case one of the generators from the refinery is out of service. On the other hand, in the alternative of integrating the generator through a three winding transformer, the tension falls are compensated by the relation between the 13.8/14.4 kv windings, it means that the tension difference of 3.04% regulates the tension in acceptable levels in the distribution switchgear for the power transference in the generator in 13.8 kv or the 34.5 kv future synchronization bus.

9 130 The electrical system fleibility and reliability in both alternatives are almost the same, for eample, the Icc 3f has 80% of interruptive capacity. Both analyzed alternatives ensure that TG-8 integration generator will be protected by over tensions because it always will have an intentional reference of their grounding neutral and there will be used a high resistance grounding neutral, what will avoid great energy flows through their winding. The alternative of using a three-phase transformer in contingence conditions, avoids the overworking of the transformer. Moreover, with the integration of a 34.5 kv synchronization bus, considered to the future implantation, the transformer keeps operating. Table 4 shows the results summary of Icc 3 f and the fall tension (Ct %) with a 115.5MW charge of the alternatives analyzed through: a) a short-circuit flow limiting reactor and b) a three winding transformer. The alternatives technical evaluation of transition stage has advantages and disadvantages. Table 5 shows technical advantages and disadvantages for the alternatives to integrate the first electrical generator into a typical refinery scheme. The two alternatives of the integration of the new electrical generation module: a) require an additional investment as transition stage between phase 1 and phase 2 and b) shows quantities of 3F and Ct % according to the regulation (ANSI/IEEE, 1993; ANSI/IEEE, 1986). The fleibility and reliability of the electrical system is improved with the use of Figure 9. Descriptive scheme but non limiting of a transition stage to connect a generator with the actual scheme in refineries through a electric limiting reactor (I). Figure 10. Descriptive scheme but non limiting of a transition stage to connect a generator to the actual refineries scheme through a three-phase transformer. (2) three winding transformer, moreover it permits the use of power equipments to be installed, instead of limiting energy reactors which will get out of service. Tables 6 and 7 show the economical evaluation of both mentioned alternatives and their associated equipments for the integration of the first generator. It is important to mention

10 Assessment and planning of the electrical systems in Meican refineries by Table 4. Comparative results table for the new generator integration. Parameter Load Scenary 1: Reactor 2: Transformer Maimum Icc 3 f 31.6 ka 29.6 ka (TBSII) (All TG s) (TBSII) Ct % Maimum A 1.86 %(TD-10) 1.87 % level (TD-10) (All TG s) Maimun Icc 3 f (TG-6: F.S.) Ct % máimum level (TG-6: F.S.) Notes: F.S. Out of service MW B 27.7 ka (TD-7) 3.04 % (TD-8) * 25.5 ka (TBSII) 2.92 %(TD-10) * New overworking generator (TG-8) Table 6. Cost of the main equipment when TG-8 is integrated through a limiting reactor with an air core (the cost of TG-8 is not included). Item Concept Characteristics 1 Reactor Icc limiting charge reactor with a 2300 A, Ω air core 4 conductors per phase of XLP wire, 15 2 Load circuit kv, class, 133%, 750 kcm caliber and an approimate length of 500 m A of nominal charge switchgear with Distribution an Icc of 40 ka, 6 cells including the one switchgear of TG-8 4 TG-8 Reception cells Two metal Clad cells 15 kv class, including 2000 A vacuum interruptor, measuring and protection kit. Cost [MUSD] $.058 $ $ $ TOTAL $ Table 7. Cost of the main equipment when the tg-8 is integrated through a three winding transformer (it is not include TG-8 cost). Item Concept Characteristics 1 Three windind transformer 2 Charge circuit 3 4 TG-8 Reception cells Distribution switchgear Three winding transformer of 35/35/35 MWA with transformation relation of 13.8/13.8/34.5 kv XLP wirw, 15 kv class, 133 %, 750 Kcm caliber for 500 m and 4 conductors per phase Two Clad metal cells, 15 kv class including 2000 A vacuum interruptor, measuring and protection kit A charge nominal switchgear including a 40 ka Icc, 6 cells including the three winding transformer Cost [MUSD] $ 1.1 $ $ $ TOTAL $ 1,775 that assenting both alternatives in economical contet, the best solution is to use the limiting reactor which safes 37.8% compared to three winding transformer; however this is a short term cost. It is considered a future 34.5 kv synchronization bus reconstructing, therefore the three winding transformer will be still used in Table 5. Technical evaluation of the first generator installation using: 1) an icc energy limiting reactor or 2) a three winding transformer. Advantages 1 2 Icc 3f 25.2 ka and optimal power flow in contingence conditions If the NES commitment fails, the turbo can feed 100% of the charge. If a generator fails, its charge bus is fed by TBS If BS fails, every generator remains with its charge bus If a switchgear is been repaired their charges can be transferred to an adjacent switchgear All the generators can operate with grounding neutral. Can receive a future growing of 60% Can receive a future growing of 30% Require the same investment because it maintain kv level as distribution tension Better feasibility for its implementation. The equipment investment will be used in future projects. Disadvantages 1 2 When a switchgear is out of service, a generator is out of service When the bus A or the bus B is out of service, a flow charge NES is lost If the synchronization bus fails, the NES is lost. It needs the greatest investment It is necessary to recharge the synchronization bus circuits which go to the TBS It is not posible to recharge the distribution buses circuits which go to the TBS If the synchronization bus fails, the refinery has to import 50 MW If the synchronization bus fails, the charge of a generator is lost Icc 3f surpass the switchgear capacity limit even though using pyrotechnics fuses or Is-limiters If the two generators fail, NES can not feed 100% of the charge There are no ground power references in synchronization bus The NES flows does not have charge bus The new generators does not have charge bus the reconstructing and the long term cost would be less, avoiding the investment of a transformer to synchronize in 34.5 kv the new generator in the future. Conclusions It is necessary to optimize and to modernize the NRI electrical systems, because it is well known that in Meico has not been constructing a new refinery since 1979 and is necessary to acquire new technology according to NOM-086 regulation for the projects of 2012 and that technology must be implanted in the mentioned refineries. The 34.5 kv BS showed in that article for two refineries can receive new charges an new generation modules, the power flow between NES and the local system is ideal and does not needs special equipment for its eecution, moreover it can be associated to two energy source for a charges bus.

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